Ferroli SUN Series Quick start guide

INSTALLATION, USE AND
MAINTENANCE
INSTRUCTIONS
INSTRUCTIONS POUR
L’INSTALLATION
L’UTILISATION ET
L’ENTRETIEN
S.p.A.
SUN
HEATING OIL
BURNER
BRULEUR À
FUEL

Index page
General information - Technical and dimensional features................................................................ 3
Main parts - Operative range of the burner ........................................................................................ 4
Electrical connections ........................................................................................................................ 5
Heating oil fuelling line ....................................................................................................................... 6
Boiler assembly - Pump pressure regulation ..................................................................................... 7
Choosing the injector ......................................................................................................................... 8
Head regulation and air flow rate adjustment - Example of combustion regulation
Position of electrodes-baffle............................................................................................................... 9
Setting at work - Work cycle...............................................................................................................10
Maintenance - Demounting and servicing the burner ........................................................................ 11
Troubleshooting ................................................................................................................................. 12
Components....................................................................................................................................... 13
List components ................................................................................................................................. 14

S.p.A.
3
SUN
Fig. 1
GENERAL INFORMATION
Ferroliisproudtopresentthisseriesofheatingoilburnersfordomesticboilers,withthermalpowerratings
of between 13,3 and 58,1 kW. A compact and attractive design make these burners fit for use with the
majority of the boilers currently available on the market.
Use of modern technologies has enabled Ferroli to produce these new appliances able to optmize the
air-fuel mixing function. This achieves high efficiency, low degrees of CO and NOx together with a very
silent flame.
Here are the more important technical features:
- Fine adjustment of the position of the combustion head in relation to the nozzle by means of a
micrometric screw.
- Accurate air adjustment on the intake.
- Airlockwithgravityclosingwhentheburnerstops.Thisnotablylimitsheatdispersionswhentheboiler
is on hold.
- Burneriscompletewithapreheateronthenozzleline.This improves combustion and ensures prompt
ignition after lengthy periods at a standstill during the colder season and when paraffinic heating oil is
used.
- The inspection and servicing operations are very convenient for all models.
TECHNICAL AND DIMENSIONAL FEATURES
Type SUN
IP40Prot. Class
220 WInput
220 - 240V 50HzEl. Power Supply
Heating oil max 20 °C 1.5 E
Fuel
70W 0.6A 2735 g/min
Motor
2x7 kV 40 mA
Ignition trasformer
Øe 64 - Øi 16 nr. 6 tagli
Fuel Nozzle
110 W
Preheater
146-48 rsx 40 pale
Fan
Thermal Power Rating kW
min.
max.
Fuel Flow Rate kg/h
min.
max.
G.6 R G.6
21,3
58,1
1,8
4,9
13,3
58,1
1,12
4,90
/
170 W
Ø91
Ø 170
Ø 140
250
286
0
Ø90
180
227
96

S.p.A.
4
SUN
MAIN PARTS
Fig. 2
Fig. 3 1
kg/h 1.5
0.6
0.5
0.4
0.3
0.2
0.1
0
∆p mbar
2.0 5.04.54.03.53.02.5
1
kg/h 1.5
0.6
0.5
0.4
0.3
0.2
0.1
0
∆p mbar
2.0 5.04.54.03.53.02.5
SUN G.6 R
SUN G.6
Pressure in combustion chamber ∆p mbar
Heating oil flow rate Kg/h
OPERATIVE RANGE OF THE BURNER
V
5
17
4
P
20
15
10
50
16
8
3
13
18
6
15
12 11 10 9
7
2
1
14
1Heating oil pump
2Motor
3Electromagnetic valve
4Burner unit
5Release button
6Mechanism
7Photoresistance
8Ignition transformer
9Burner coupling flange
10 Injector line with preheater
11 Ignition electrodes
12 Nozzle
13 Air lock adjuster screw
14 Spina allacciamento elettrico
15 Fan
16 Combustion head adjustment
17 Pump pressure adjustment
18 Pressure tap
Key

S.p.A.
5
SUN
ELECTRICAL CONNECTIONS
Fig. 4
Key
CO Hour counter
FFuse
FR Photoelectric resistance
IG Main switch
LS Safety light
MB Burner motor
PB Burner tap
PR Preheater (G6R only)
SC Plug
TA-TC Boiler - room thermostat
TR Ignition transformer
TS Safety thermostat
Tm Minimum rating thermostat
VE Electromagnetic valve
The following electrical connections are at the installer’s charge:
- power supply line
- thermostat line
- possible shutdown indicator light and/or hour meter
Attention
- do not switch the neutral and phase wires
- always install a good ground connection
Preheater cable
N
B
M
GN
4321
Connection for without
preheater version
PREHEATER CONNECTION
FR
12 34567891011122
TR
M
1~
MB
VE
Tm PR
PB SC
L1 NT1 T2 S3 B4
L1 N T1 T2 S3 B4
w
h
TA - TC
LS
NNNPh
IG
F
TS
CO

S.p.A.
6
SUN
HEATING OIL FUELLING LINE
Attention: Before starting the burner, check that the fuel return pipe is not clogged. Excessive over-
pressure would break the pump retaining component.
Install a filter on the fuel supply line.
H
(m)
0.5
1.0
2.0
1.5
L (m)
Øi 8 mm. Øi 10 mm.
10
20
40
60
20
40
80
100
HYDRAULIC CIRCUITS
AGravity supply
BSuction supply
CSiphoned supply
DRing supply
Nota: Add0.25meterstothepipelengthforeach
elbow or gate valve (load losses).
LTotal length of intake pipe including vertical
sections
HDifference in level
Øi Inner pipe diameter
H
(m)
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
25 60
L (m)
Øi 8 mm. Øi 10 mm.
21
18
15
12
10
8
6
50
44
38
32
26
20
16
H
(m)
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
25 60
L (m)
Øi 8 mm. Øi 10 mm.
21
18
15
12
10
8
6
50
44
38
32
26
20
16
Fig. 5a
Fig. 5b
Fig. 5c
Fig. 5d
A
B
C
D

S.p.A.
7
SUN
4
5
090
6030
3
4
5
2
1
SUNTEC AS
DELTA VM1 RL2
Fig. 6
-Insert screw 2 (m8x25) into flange 3
-Insert flange 3 into the boiler using the 5 screws (NR. 4 M8x30) with insulating seal 1 in between.
-Insert the burner into the boiler flange and fix it to screw 2 with nut 4.
PUMP PRESSURE REGULATION
DANFOSS BFP 11 R3
m h
2
O
Type BFP
NO.
V P
MADE IN
DENMARK
1
2
6
54
3
4
6
V
P
230v. 50Hz. VA. 11 Cod. M81
DELTA
5
1
2
3
PV
1
2
3
65
4
Fig. 7
BOILER ASSEMBLY

S.p.A.
8
SUN
CHOOSING THE INJECTOR
The injector must be chosen according to the power rating of the boiler flue, remembering that heating
oil has a heat value (N.H.V.) of 10200 kcal/Kg. The chart gives the flow rate or consumption in Kg/h and
kW of heating oil according to the size of the injector (in GPH) and the pump pressure (in bar). When the
burner has a preheater, the effective capacity will be about 10% lower than the values in the chart.
Injector
G.P.H.
0,40
0,50
0,60
0,65
0,75
0,85
1,00
1,10
1,20
1,25
1,35
1,50
1,65
1,75
2,00
2,25
2,50
3,00
1,27
1,59
1,91
2,07
2,38
2,70
3,18
3,50
3,82
3,97
4,29
4,77
5,25
5,56
6,30
7,15
7,95
9,54
7
1,36
1,70
2,04
2,21
2,55
2,89
3,40
3,74
4,08
4,25
4,59
5,10
5,61
5,95
6,80
7,65
8,50
10,20
89
1,44
1,80
2,16
2,34
2,70
3,06
3,61
3,97
4,33
4,50
4,87
5,41
5,95
6,31
7,21
8,15
9,01
10,82
1,52
1 ,90
2,28
2,47
2,85
3,23
3,80
4,18
4,56
4,75
5,13
5,70
6,27
6,65
7,60
8,55
9,50
11,40
10
1,59
1,99
2,39
2,59
2,99
3,39
3,99
4,38
4,78
5,00
5,38
5,90
6,58
6,98
7,97
8,97
9,97
11,96
11
1,67
2,08
2,50
2,71
3,12
3,54
4,16
4,58
5,00
5,20
5,62
6,24
6,87
7,29
8,33
9,37
10,41
12,49
12
1,73
2,17
2,60
2,82
3,25
3,68
4,33
4,77
5,20
5,40
5,85
6,50
7,15
7,58
8,67
9,75
10,83
13,00
13
1,80
2,25
2,70
2,92
3,37
3,82
4,50
4,95
5,40
5,60
6,07
6,75
7,42
7,87
8,99
10,12
11,24
13,49
14
1,86
2,33
2,79
3,03
3,49
3,96
4,65
5,12
5,59
5,80
6,28
6,98
7,68
8,15
9,31
10,47
11,64
13,96
15 17
1,98
2,48
2,97
3,22
3,72
4,21
4,96
5,45
5,95
6,20
6,69
7,43
8,18
8,67
9,91
11,15
12,39
14,87
16
1,92
2,40
2,88
3,12
3,61
4,09
4,81
5,29
5,77
6,00
6,49
7,21
7,93
8,41
9,61
10,85
12,02
14,42
6
1,18
1,47
1,77
1,91
2,2
2,5
2,94
3,24
3,53
3,68
3,97
4,42
4,86
5,15
5,89
6,62
7,36
8,83
Pump pressure kg/cm
2
Flow rate at injector outlet kg/h

S.p.A.
9
SUN
POSITION OF ELECTRODES - BAFFLE (Fig. 9)
After having mounted the injector, check
thattheelectrodesandbafflearecorrectly
positioned according to the above listed
measurements.
Always check the measurements
whenever operations are carried out on
the head.
3
1
L
45.0°
6.5
3.5
Fig. 9
kW
23,3
34,9
46,5
kcal/h
20.000
30.000
40.000
Burner
flow rate
Kg/h
2,176
3,25
4,35
US
Gall/h
0,6
0,85
1,1
1,0
Angle
60°
60°
60°
60°
Code
3560154/0
3560134/0
3560128/0
3560127/0
Pump
pressure
Bar
12
12
12
12
Air
regulation
Tacca
5
10
15
15
kcal/h
22.200
33.200
44.400
kW
25,8
38,7
51,6
Tacca
6
10
15
18
L
18
22
27
31
*** * ** *
Delivered heat
output Head adjustment
MODEL
BOILER
GN1.02
GN1.03
GN1.04
Heat rate Injector
COMBUSTION HEAD AND AIR
DAMPER ADJUSTMENT (Fig. 8)
Thecombustionhead is adjusted accord-
ing to burner flow rate. To adjust, rotate
the adjustment screw (B) clockwise or
anticlockwise until the notch on the rod
“A” coincides with the indicator.
This modifies the position of the deflec-
torinrelationtothe draught tube and con-
sequently the passage of air.
Theairflowrate is adjusted via screw“C”.
When the burner shuts down, the air
damper closes automatically.
EXAMPLE OF COMBUSTION REGU-
LATION
Theinjector,pumppressure,combustion
headadjustmentandair flow rate regula-
tionmustbeestablishedaccording to the
flow rate required by the boiler, as indi-
cated in the following chart check com-
bustion. Fig. 8
C
A
B
* Regulations for without preheater burner version

S.p.A.
10
SUN
VE
GP
VE
GP
a) Oncethethermostaticlinehasbeenclosed,theburnermotorwillstartoperatingtogetherwiththepump
the intaken heating oil will be totally conveyed towards the return side. The burner fan and ignition
transformer will also be operating and the appliance will proceed with the following phases:
- flue pre-ventilation
- pre-flushing of part of the heating oil circuit
- pre-ignition, with discharge between the tips of the electrodes.
b) At the end of the pre-flushing phase, the electromagnetic valve will open and the heating oil will reach
the injector from which it will be finely atomized.
Contact with the spark between the electrode tips will form the flame. The safety time will now start.
WORK CYCLE
SETTING AT WORK
1) Preliminary operations
- mount the pressure gauge and vacuometer on the pump (remove after start-up)
- open the gate valves along the heating oil pipe
- power the equipment by means of the main switch
- close the thermostat line (boiler/room)
- release the appliance (by depressing the red button).
2) Start-up
Fig. 10
A' A B C D
1
8
3
3
7
4
11
12
tw t1
t3 t3 n
t2
Preheater with TM
Motor
Transformer
Electromagnetic valve
Photoelectric resistance
Room-boiler thermostat
TA - TC
Pr
Tm
MB
TR
VE
FR
Signals required on input
Signals on output
TA-TC Room thermostat
FR Photoelectric resistance
MB Burner motor
TR Ignition transformer
VE Electromagnetic valve
Tm Heater Pr minimum
thermostat
AStart-up without preheater
BFlame on
CNormal operation
DAdjustment stop (TA-TC)
A' Start-up with preheater
t1 Pre-ventilation time: 13 sec.
t2 Safety time: 10 sec.
t3 Pre-ignition time: 13 sec.
t3n After-ignition time: 15 sec.
tw Preheating time: 60/90 sec.